Mea SMAC 35DG Owner's manual

7202-D0001-12
SMAC 35DG/WG/5 IN 1
15HP
Owner’s / Operator’s Manual
35 CFM Diesel Driven Air Compressor C/W
Generator/Welder
Revision: 12.1
Reviewed: 16/12/2021

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THIS PAGE IS LEFT
BLANK
INTENTIONALLY.

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MEA Product Warranty Registration Form
THIS FORM MUST BE COMPLETED AND
RETURNED WITHIN 30 DAYS OF INSTALLATION
OR
WARRANTY WILL BE VOID

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MEA Product Warranty Registration Form
This form must be completed and returned to MEA at the time of
Installation. Warranty will be void if this form is not received by MEA
within 30 days of installation.
MEA Dealer Information
Company Name: _____________________________________________________________
City: _______________ State: ___________________ Country: ___________________
MEA Installer Information
Company Name: ______________________________________________________________
City: _______________ State: ___________________ Country: ___________________
Installation Date: _______ / ________ / ______
Day Month Year
Owner Information
Company Name: ______________________________________________________________
Address: _____________________________________________________________________
City: _______________ State: ___________________ Country: ___________________
Postcode: _________________________ Phone #: ________________________________
Product Information
MEA Serial Number: __________________________________________________________
Model Number: _______________________________________________________________
CUT HERE

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TABLE OF CONTENTS
1. COMPRESSOR / COMPRESSED AIR SAFETY..............................................................6
3. SPECIFICATIONS............................................................................................................9
4. OPERATING PROCEDURES.........................................................................................12
5. INSTALLATION..............................................................................................................16
6. SCHEDULE MAINTENANCE.........................................................................................23
7. SPARE PARTS AND SERVICE KITS............................................................................25
8. TROUBLESHOOTING....................................................................................................26
9. DRAWINGS & ILLUSTRATIONS...................................................................................28
10. WARRANTY .................................................................................................................44
11. MOBILE ENERGY AUSTRALIA - CONTACTS............................................................46
Both the MEA Product Warranty Registration form (located at the FRONT of this Manual)
and the Kubota Engine Warranty Registration form (located at the back of this manual)
are to be returned to MEA.
FAILURE TO RETURN EITHER FORM MAY RESULT IN THE PRODUCT
WARRANTY BEING VOID.

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1. COMPRESSOR / COMPRESSED AIR SAFETY
(COMPRESSOR / COMPRESSED AIR)
MEA DISCLAIMS ALL LIABILITIES FOR DAMAGE OR LOSS OF EQUIPMENT AND PROPERTY,
PERSONAL INJURIES (INCLUDING DEATH), AND CONSEQUENTIAL DAMAGES ARISING OUT OF
ANY MEA SYSTEM NOT USED IN ACCORDANCE WITH THE OPERATOR’S MANUAL.
ALL UNITS ARE SHIPPED WITH A DETAILED OPERATOR’S MANUAL. THIS MANUAL CONTAINS
VITAL INFORMATION FOR THE SAFE USE AND EFFICIENT OPERATION OF THE UNIT. READ THE
OPERATOR’S MANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THE
INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE.
Care is required when working with an air compressor or compressed air. Compressed air is one of the many
way’s energy can be stored. Releasing the stored energy in an uncontrolled manner can result in catastrophic
consequences. Death and permanent disability are possibilities that can occur. The following are suggested
as minimum requirements to be followed when operating the MEA SMAC system. It is important that each
work site shall perform a risk analysis and produce a procedure to eliminate or control the hazardous
condition to minimise the risk to personnel and equipment. Health and Safety Regulations necessitate that
this is a compulsory process to be carried out on each site. These, together with site specific safety
procedures will help to minimize the risk to accidents, personnel injury, and loss of life. It is the responsibility
of the employer to ensure that the work site is safe for all employees and that the safety procedures are
followed by all employees.
SAFETY WHEN OPERATING AN AIR COMPRESSOR
•Do not bypass or disable the oil temperature and pressure sensors –unless planning on running to
failure (MEA does not recommend the practice).
•Do not expose the tank or compressor to extreme heat.
•Do not perform any service or repairs until the system has been completely relieved of air pressure.
•Maintenance and repairs on the system should only be done by qualified personnel.
•Do not operate the compressor while driving.
•Do not tamper with the pressure relief valve.
•Follow safe work practice, wear the appropriate personal protective equipment (PPE) when operating
air-powered equipment, particularly eye and hearing protection.
•Avoid contact with rotating components, ensure all safety guards are in place.
•Avoid all contact with pressurized air. If it penetrates the skin, it can enter blood stream and cause
death.
•Vaporized oil propelled by high pressure is an explosive mixture. To prevent compressor explosion
or fire, make sure that the air entering the compressor is free of flammable vapours.
•Do not breathe the compressor air, vaporized oil is a respiratory hazard.
•Stay clear of all moving parts when the system is operating.
•Follow safety procedures for tyre service operations as set by the authority.

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2. INTRODUCTION
This MEA (SMACD-G/WG) Service Maintenance Air Compressor utilises a diesel engine to power the
compressor and generator or welder generator. Only those who have been trained and who have read and
understand the operator and installation manual should operate and install the MEA (SMACD-G/WG/ 5 IN 1).
This manual contains vital information on integrating the compressor system into the vehicle system and to
ensure that it is installed and operated in a safe and efficient manner.
Detailed Information on the compressor, generator/welder, 5 IN 1 generator and the engine are supplied
separate to this Owners / Operators Manual.
The specifications on the following pages are an overview of the major components used on SMAC.

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INTRODUCTION - continued
The following is a view of SMAC fitted with the generator option.
Detailed Information on the compressor and the engine are supplied separate to this Owners / Operator manual.
The specifications on the following pages are an overview of the engine and the compressor used on SMAC35-
DG.
The following is a view of SMAC fitted with the Battery Fuel module option.

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3. SPECIFICATIONS
Compressor Type: Oil injected rotary screw compressor
Drive System: Diesel powered via direct mechanical coupling
Control: Pneumatic
Maximum Air Delivery 35 CFM @ 150 psi
Pressure Regulation: Mechanical inlet control valve modulates flow in response to demand
Inlet Valve Regulation Pneumatic
Engine Control System: Pneumatic speed control, engine and compressor high temperature and
pressure engine shutdown system
Safety Features 200 PSI relief valve in compressor sump
Temperature safety sensor in the compressor
Rapid blow-down valve to discharge system pressure on shutdown
Lubrication: All replacement compressor oils must be approved by MEA prior to use.
Warranty will be nullified if oil has not been approved.
MEA certified and approved semi synthetic compressor oil
Part Number 10019 –P002
Quantity of Compressor Oil Required –4 Litres
Filters Paper-type replaceable air filters
Spin-on type fuel filter
Spin-on type compressor oil filter
Spin-on type Coalescing filter element

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SPECIFICATIONS - Continued
Generator Option: Single or 3 Phase Generator, Generator / Welder or 5 in 1 Generator options
Single or 3 Phase Generator Features
•2 Poles
•Single Phase AC 5 to 8.5 kVA
•3 Phase AC 7.5 to 10 kVA
•IP23
Generator Welder Features
•2 poles brushless alternating-current rotating welders
•Protection: IP 23
•Weldable electrodes: rutile
•Supplied with auto resettable thermal breaker against overload
•Can also be used as single-phase alternator
5 in 1 Generator features
•2 Poles
•DC welder with Arc Force regulation and remote-control connector
•AC generator with single & three-phase outputs
•Battery charger with protection device against polarities inversion 12/24/36/48
•Jump Starter V.13/350 Amps in one shot

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SPECIFICATIONS - continued
Engine Model: Kubota Z602
Engine Type: 2 Cylinder, water cooled, Diesel Combustion Engine
Power (continuous): 10 Kw (13.5 HP) @ 3600RPM
Electrical System: 12 Volts DC
Maximum RPM: 3160 (max bare speed) in Generator Mode
Direction of Rotation: counter clockwise (viewed from flywheel)
Engine Control System: Electric push button start pneumatic speed control via air cylinder. (Older
model uses key start)
Engine Protection: Engine low oil pressure and high-coolant temperature sensors.
Lubrication: MEA approved oil to meet strict emission control regulations, min. class “CF”
or better is required. If oil does not meet the minimum requirements, all
warranty will be nullified.
IMPORTANT:
Engine oil should be MIL-L-2104F or have properties of API classification CF
grades or higher. Change the type of engine oil according to the ambient
temperature.
Above 25°C (77°F) SAE30 or SAE10W-30 or SAE15W-40.
0°C to 25°C (32°F to 77°F) SAE20 or SAE10W-30 or SAE15W-40
Below 0°C (32°F) SAE10 or SAE10W-30 or SAE15W-40
Engine Oil quantity 2.5L
Filters: Air Filter - Paper-type replaceable (Not Possible to Clean)
Spin-on type fuel filter (Not Possible to Clean)
Spin-on type oil filter - Spin on type (Not Possible to Clean)
Engine fuel filter –In Line Element (Not Possible to Clean)

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4. OPERATING PROCEDURES
PRE-START CHECK EACH DAY
1. Check the oil level in the engine.
2. Check the water level in the engine.
3. Check the oil level in the compressor
4. Check all hoses are secured and not damaged. Replace all damaged hoses before starting.
5. Check all electrical cables are secure. Secure all cables that are not tied down.
6. Check the air inlet and air filter on the engine are clear.

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OPERATING PROCEDURES - continued
STARTING / STOPPING DIESEL ENGINE AND COMPRESSOR –NEW CONTROL BOX
(INTRODUCED: 29/06/16) Note: Wiring harness has blue trace for ID. Not interchangeable
to previous version i.e., key ignition starts.
STARTING THE DIESEL ENGINE
1. Check the COMPRESSOR ROCKER SWITCH is set to the OFF position (centre position).
2. Press the ON/OFF/GLOW rocker switch to the LOWER POSTION –this is the Glow hold and it will
disengage if you release. Do not hold this position for longer than 15 seconds. The system could be
damaged should you extend the time beyond the 15 seconds. Releasing glow hold will leave the system
in OFF position (middle position).
3. Ensure ON/OFF/GLOW Switch still in ON position (Upper position). Start the engine by depressing the
START SWITCH –The engine should turn on immediately. Hold the switch for no longer than 10
seconds.
4. If the engine does not start, check the fuel tap if there is one and repeat the process described in 2 and
3 above. The maximum number of attempts should be limited to 4 and after this; the operator should
seek assistance from a mechanic.
5. Allow the engine to run at no load for 2-3 minutes. This will allow the engine to warm up and lubrication
system to be fully operational before the load is applied.
STARTING THE COMPRESSOR
1. Set the COMPRESSOR SWITCH to the ON position. This will engage the compressor load solenoid.
The engine speed will increase until the pre-set regulated pressure is reached.
2. Listen for air escaping from the pressurized air system. Ensure all airline taps are closed so that
compressor outlet air can reach regulated pressure.

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OPERATING PROCEDURES –continued
3. If the escaping air is from a broken pipe or connection, turn the COMPRESSOR SWITCH to the OFF
position. Stop the diesel engine. Advise the maintenance department for their assistance.
4. The engine will reduce its RPM when the compressor reaches the pre-set regulated pressure. The
compressor is now ready to be used. (It should be noted the pre-set regulated pressure can be adjusted
via the regulator control valve. It is recommended that your maintenance department does this if
required.)
5. The compressor is ready to use.
STOPPING THE COMPRESSOR UNIT
1. Disengage the compressor by moving the compressor engage switch to the “Compressor Off” position.
2. The compressor will shut down and bleed off pressure. The engine will come down to idle speed.
3. It is good practice to allow the engine to run under no load for 2-3 minutes.
4. Turn the engine off by pressing the ON/OFF/GLOW rocker switch to the centre position. If you hear a
slight “hissing” noise this is normal, the compressor is bleeding off excess pressure out of the system.
OPERATING THE GENERATOR (OPTION)
1. Start engine as per previous instruction.
2. Plug the electrical load into the outlets and switch outlets on.
3. As soon as the device is switched on, the automatic current sensing device will unload the compressor
and either increase or decrease the RPM of the engine to maintain a constant 3000rpm thus maintaining
the load until the load is switched off.
4. When the load is switched off the engine will idle down in under 10 seconds.
Note:
When operating the SMAC unit, only one device can operate at one time, either the compressor or the
generator/welder generator. When operating the compressor, the diesel engine will increase speed until it
reaches 3100rpm to deliver 35cfm. When using the generator, the compressor will be unloaded through the
unloading valve. The diesel engine will maintain a constant 3100rpm to ensure consistent power regulation to
the generator.

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OPERATING PROCEDURES –continued
OPTIONAL VRD & Remote Mount VRD
The VRD relocates the welder/generator controls to a more convenient location as well as providing added
safety when welding. The VRD control box visually shows when it is safe to weld. The original controls on the
generator are blanked off and rerouted to the VRD control box.
Below pictured is the SMAC-35-WG/VRD box mounted to the side of the unit. The electrical schematic for the
VRD control box can be found in the appendix.

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5. INSTALLATION
SMACD unit consists of a rotary screw type driven by a diesel engine. Compression occurs when inlet air (at
atmospheric pressure) enters a chamber where it is trapped between the rotating rotor lobes. A lubricated pitch
line provides sealing. As the lobes mesh, they reduce the volume of the air, compressing it to the desired
pressure.
The system has a two-stage air/oil separator. The first separation stage consists of baffles, which perform
mechanical separation. The second stage uses a special separation element, which delivers dry air to the outlet.
The second stage is a spin-on type coalescing filter.
Pressure regulation is achieved by adjusting the pressure regulator valve mounted in front of the compressor
(Silver adjustable valve). The system pressure is pre-set at 150 psi. To reduce the pressure, either adjust the
regulating valve or use a Filter Regulator Lubricator (FRL) to achieve the final tool pressure.
ENSURE THAT THE WATER SEPARATOR IS MOUNTED AS FAR FROM THE COMPRESSOR AS
POSSIBLE AND THAT IT HAS AT LEAST TWO METRES OF HOSING BETWEEN THE COMPRESSOR
DISCHARGE AND SEPERATOR INLET.
The compressor air intake is protected by a paper-type replaceable air filter, and a spin-on type oil filter for the
oil side and a coalescing filter for final oil removal from the air.
Safety features included in the compressor are:
▪200 PSI relief valve in separation manifold.
▪Blow-down valve to discharge system pressure on shutdown - will not allow compressor
restart until system pressure bellow 5PSI.
▪Over temperature safety sensor in the compressor oil.
▪Over pressure control mounted at the minimum pressure valve.
▪Do not disable or bypass the over-temperature shutdown circuits. Failure of the
shutdown system could result in equipment damage, injury or death.
A liquid-to-liquid air cooler with thermal bypass valve maintains operating temperatures in an optimal
performance range. This helps to increase system durability and reduces the temperature of the compressed
air.

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INSTALLATION - continued
The information in this section is very important for proper operation of the compressor. Read these
requirements before beginning installation. The following is a view of the compressor/diesel engine unit.

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INSTALLATION –continued
1. General Consideration Mounting the Compressor Unit
The starting point for the installation is a quick overview of the requirements. Some of these points will
be dealt with in more detail further on in this text. Things that should be considered now are as follows.
1. The unit should be installed in a well-ventilated area.
2. The unit will need to be installed level and any variation in the frame to be supported via washers
for spacers and properly secured to the vehicle by means of 5.8 grade fasteners.
3. In installation, the unit should be orientated s that the sight level glass for oil level can be
checked easily.
4. It should also allow to be serviced the unit easily without having to disconnect lines or remove
and reposition the unit.
5. The unit should be protected from excessive exposure to the elements and possible incidental
damage from other operations.
6. The unit should be installed in an area away from heat sources such as engines, exhaust
systems or other components that generate heat.
7. The unit should not be installed in a location where it will be exposed to high contamination
levels or combustible gases.
8. The engine exhaust should be routed away from the compressor unit. The engine exhaust
should be in an area where the exhaust CANNOT be filled up with rain (an exhaust flapper is
fitted to the exhaust) however the exhaust must not face directly down to the ground.
2. Mounting of Compressor Unit considering Ventilation
It is not possible to make absolute recommendations regarding ventilation because of the widely
differing circumstances that are possible. Duty cycle, ambient temperature and enclosure shape are
some of the important variables. Ideal ventilation will provide good airflow through the unit with no
restrictions. Broadly speaking, there are two ways in which the SMAC compressor can be mounted.
1. Top or Deck Mounting
This is the preferred mounting location. Placing the unit in an area where there are no restrictions on
the intake of fresh air and exhausting of hot air and exhaust gases. This provides the best cooling and
ensures reliability and life for the compressor / diesel engine driven unit.
2. Enclosed Mounting
It is important that discussion occurs between the manufacturer and the person installing the unit when
it is to be placed in an enclosed area. Ventilation is one of the most important things to consider when
looking at the installation of a compressor/diesel engine driven unit in an enclosed area. It is important
that the air intake to the compressor and the engine exhaust are located outside of the enclosed space.
The unit generates a considerable amount of heat when running. Proper ventilation is vital for ideal
operation and to avoid damage to components. Ensure there is a minimum of 10" (250 mm) clearance
between cooler grills on SMAC and any other components mounted on the vehicle. It is strongly
recommended that the installation is tested in the event that the unit is installed in an area considered
to be enclosed mounting. The following is a method suggested for testing.
2.1 It is best to test the installation at the hottest expected ambient temperature.

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INSTALLATION - continued
2.2 Setup and run the system at 120 PSI. This can be done by installing a ball valve on the air
outlet pipe and adjusting the opening of the valve so that the compressor is running continuously at 120
PSI.
2.3 Record the engine, compressor, and current ambient temperature for future reference.
2.4 Run the system at full load for at least one hour or until the temperatures stabilizes.
Temperature stabilizing means there is no rise in temperature for 15 minutes when the compressor is
running at the rated load.
2.5 Record the engine and compressor temperatures every 10 minutes.
2.6 If the system over-heats, the ventilation is not sufficient, review the installation, make changes
as needed, and repeat the test.
3 Engine Exhaust consideration when installing Diesel Engine Driven Compressor Unit
In cases that the exhaust system needs to be ducted away from the engine assembly, the following are
a minimum that should be considered
▪The exhaust pipe needs to be adequate for the engine.
▪There needs to be a flexible joint at the point where the extension is connected to the exhaust
system of the Diesel Engine Driven Compressor Unit.
▪Ensure the exhaust pipe has suitable clearance and does not meet anything.
▪Ensure that if the exhaust system has a method to prevent water from entering the exhaust
system.
▪Ensure exhaust from the diesel engine is routed in a way to prevent recirculation back into the
unit.
4. Securing the Diesel Engine Driven Compressor Unit to the body of the vehicle.
It is important to consider maintenance needs, (daily needs), service requirements, electrical
connections, air connections, location of control panel before the SMAC is secured to the body of the
vehicle.
▪Locate a suitable mounting position for SMAC. Place the unit and check for clearances to any
other objects.
▪There are four weld nuts located at the four corners of the bottom formed plate which can be
used as mounting bolt locations. Holes can also be drilled through the bottom of the formed
plate if alternate locations are required.
▪Drill four holes in mounting surface and secure the SMAC to the truck. Use a minimum of 4 –
M12 bolts.

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INSTALLATION –continued
5. Connecting Truck Electrics to the Diesel Engine Driven Compressor Unit
Electrical connection of SMAC to the truck is very simple. The entire control system is mounted in the
SMAC.
1. The SMAC needs to be connected the truck battery. A minimum of 25mm cable is required for
the connection because the SMAC is started using the truck battery. SMACD units are 12 Volt
DC. If a truck is 24 Volt DC (Two of 12 Volt DC batteries are supplied in the truck), connection
for the SMAC Unit will be across 1 of the batteries.
2. Start switch control box which includes the compressor load and unload switch needs to be
connected to the SMAC front panel via the Deutsch plug provided at the end of the 5-metre
cable of the control box. It should be noted; this switch box can be mounted in the cab of the
vehicle if an extension harness is purchased or any location on the truck body.
6. Connection of the Diesel Engine Driven Compressor Unit to the fuel tank.
It is normal to use the trucks fuel tank for all models of the SMACD. The SMACD has as standard a fuel
pump built into it. It is suggested that an additional electrical fuel pump is installed if the compressor
unit is installed 20” (500 mm) above the height of the truck diesel tank. The following is the method for
connecting the fuel to the compressor unit.
1. Cut the feed and return lines at the tank. Install the tees into the cut pipes.
2. Install the provided check valve at the T-Piece of the feed pipe.
3. Connect the diesel feed pipe to the compressor unit from the check valve. Connect the return
line from the compressor unit to the return line tee.